Random 78 "braun" project.

hey hey i bought a 78 W germany rabbit
i have been working on it since the day I got it

i need it to run me around to school and for a month to work while i repair the 81's transmission this spring

trying to get this thing going with half of it scattered on the floor (neatly) and the other half in the rear compartment organized and boxed up including ziplocked by category!

here are some photos of things i have done
removed, changed, replaced, whatever

hope someone finds this useful other than enjoying the photos

thanks

*oh, i have some other photos on camera
will upload them later*

and before/after

whats next?
well i have some connectors for the WUR and CSV but not the TTS, it has 3 wires
replacing those with upgraded 90-2003 connectors

and putting the wiper stalk assemblies back in

thats all
will have photos of more things later (in this post, not second post)

ugghh....
ah...oohh....ugggghhh.....
this AC core is going to scrap. JUNK ---edit--- just the AC not the whole box....duh, i need heater
a (bad) 7/1977 load reduction X relay. forgot to test it, will test it later..
I DID NOT break these, they were broken when I bought the car!!
adding some hub clip retaining bolts, perfect fit, stainless steel

ok so working on the gauges
these are going in the radio slot using the "lock" housing from the radio

built the front using smoked plexi glass
fugged the last hole, it was off 2-3mm from center
best i could do with a hole saw
last pic you can see i am wiring it
each gauge is in parallel so they each receive the same voltage
the blue wire is ground for the lights which get wired next
after i figure if the wire im going to splice in is + or -
i dont have an oil pressure sender yet, but it gets wired and connected
a dead wire will be located into the engine bay until then
nearly certain the CELS gauge is correct for the wiring
it kicks on when powered but havent tested its temp reading yet
the BAR gauge is definately wired correct to the G connection
so unsure if it is _|_ or G for the CELS gauge that goes to the sender I put on the coolant outlet
will be able to test that next week and either way its not a major re-wiring to switch

distributor work
the distrubutor in the picture came with the car in the trunk
i am positive it was the factory 78 because it does not have holes for frequency valve
the one running on the car has the frequency valve plugged and banjo bolt swapped over

cleaned the distributor, replaced the o-rings on the system pressure valve
cleaned 3 of the 4 injector filters, one would not come out at all so just sprayed it heavily..
removed the WUR and cleaned the filters and rust
inside looked good, o-ring was good, that was clean
pulled the CSV and cleaned that, replaced the gasket and both bolts
all new crush washers
also new rubber fuel box gasket
runs smoother with the plunger and float all cleaned and sparkling

here is my fuel pump relay switch
when "off" the switch is not contacting the battery pin
switched on it goes from pin 30 battery -> fuse -> switch to pin 87
fuse had to be located outside of the housing for replacement purposes
pins 85/86 are not connected to anything, they just hold the relay in the socket

decided to take out the GC now and swap in my prepared GP
not going to do my 81 GP rebuild right now and it seems to be running "OK"
btw did i mention i hated this thing @60mph? 3400rpm is B!S!
complete swap took 6 hours to perform
.......by myself......i can benchpress a 75lbs transmission...and i dont even weigh close to twice as much

lots of fun
i used 97-2003VW parts from various junkyard cars
lots of good removable fuses/relay connections under the dash for this
lets just say....my box of "parts" was a legit steal of a price.....

hail shots

you can see the black top I did
which was great
much better than the lumpy primer when I got the car

it was spotted with surface rust everywhere under the primer
i got it completely to bare metal
por15 then primer then black, more black more black, then gloss

the hatch was previously sandblasted...hrrmm...
you can tell because the glass in one area is damaged from the sand
got it down to bare metal on the outside also
tons of sanding, por15, primer, some beautifully unmatched paint but it was smooth
my touch ups on it show through clearly

tach & door cards

modded and installed my woodgrain tach
tach works, all lights work except EGR/OXS, and...the ground for the Oil pressure light is dead
swapped my speedo/odo over because i hate trip-meters, and it didnt have a decimal
filled the hole for the trip button with epoxy

then decided its time to fix my door cards, install chrome handles
and figure out what the banging is on the passenger door...

the door handle foam disentegrates instantly....as expected
bought new foam and cut it out to fit
the window crank foam is the same kind and although 35 years old, still holds up great

lubricated the window guides and adjusted the window slightly
the water/vapor barrier is .002mil 20inches x 25ft...same went onto my 81 so why not
i used rubber cement to help attach it to the metal compared to taping it entirely on my 81

the speakers, forgot to measure them, but they are Jensen...kind of odd looking so not entirely sure how stock they are

didnt get pics of all the passenger work but the banging sound was the window guide
the lower end is metal instead of a plastic tube
so the metal was Loose... and banging on the door metal
i ziptied it and added some foam and a cloth pad, it became much quieter

i know the whole process isnt the best vapor guard but it works well enough
the stock stuff was mostly still there in fair condition and surprisingly not falling apart
a few extra steps i should have done but i tend to skip them

oh, the whole reason for this epoch?
the driver side door check was broken...wanted to fix it
and the passenger side was banging